2026 Zou Battery metals and impurities in black mass leaching

With the global transition toward sustainable energy systems, lithium-ion batteries (LIBs) have become indispensable in portable electronics, electric vehicles, and renewable energy storage. Nonetheless, the rapid accumulation of spent LIBs presents environmental, safety, and resource challenges. Efficient recycling and recovery of critical materials like Co, Li, Ni, Cu, and graphite are therefore vital for the advancement of a circular and sustainable energy economy. Furthermore, the behaviour of impurities such as Si and Al must be considered to ensure recycling process efficiency and product purity. This study systematically investigates the leaching and purification behaviour of industrially relevant battery metals and impurities during the black mass recycling process, focusing on achieving optimal recovery rates while minimizing contaminant presence. Through controlled experiments, comprehensive data on the leaching dynamics and interactions between different materials are presented, securing a foundation for future research into enhancing the recyclability of spent LIBs. Results indicate significant variations in leaching efficiency based on process conditions, highlighting critical parameters for designing effective recycling systems while ensuring environmental safety and material recovery. These findings contribute to the growing body of knowledge necessary for improving the sustainability of lithium battery disposal and recovery processes.